BASED ON EXPERIENCE

TGE GAS ENGINEERING

EPC EXECUTION OF BOREALIS ETHANE TANK PROJECT

www.tge-gas.com 24/10/2016 Page 1

CONTENT

Overview on the Services and Experience of TGE Gas Engineering GmbH

Project Overview and Process Description

Construction Phase

Pre-Commissioning and Commissioning

Time Schedule

www.tge-gas.com 24/10/2016 Page 2

COMPANY PROFILE
TGE Gas Engineering GmbH (TGE) is one of the LIQUEFIED GAS STORAGE
world‘s leading contractors for projects involving the CAPACITY PERFORMED (m³)
storage and handling of liquefied gases in the energy Status Sep. 2016
and petrochemical/chemical industries. 6.000.000

TGE has over 30 years of experience in this field,

providing full range of services from concept 5.000.000
/feasibility studies through to Lump Sum Turn-Key
Project execution.
4.000.000
Our target is to provide to customers the added value
based on our experience and Know-How in delivering
“millions of m³” of Liquefied Gas Storages and 3.000.000
Handling Facilities.
TGE is a technology focused company that is active 2.000.000
worldwide with main operating units throughout
Europe and Asia.
1.000.000

0
Overall LNG Ethylene / Propylene,
capacity Ethane LPG, etc.

www.tge-gas.com 24/10/2016 Page 3

SCOPE OF SERVICES BOREALIS
Consultancy Detailed Engineering
Technical and Commercial Feasibility Studies Procurement/Procurement Services
Site Selection Construction/Construction Services
Conceptual Design Supervision Services
Environmental Impact Assessment (EIA) and Pre-Commissioning and Commissioning Services
HAZOP Studies
Start-Up/Shut Down Services
Capital Cost (CAPEX) and Operating Cost
(OPEX) Estimation Selection and Training of Operators

Business Plan for Capital Investments and Operations Operation and Maintenance Services

Basic Engineering and Front End Engineering Design Life-Cycle Engineering Studies and Plant
(FEED) Life-Cycle Optimisation

www.tge-gas.com 24/10/2016 Page 4

PROJECT OVERVIEW
DESIGN BASIS

Medium Main equipment

Liquid Ethane In-tank Pumps (3 x 50% capacity)
Storage Tank Screw Compressor Package (2 x 50% Capacity)
Ground Flare System
Full Containment Storage Tank
Utilities
Working Volume 52,000 m³
Design Conditions Design Requirements
-4.5 to 300 mbarg Unloading Rate
-115°C to Ambient Sendout Rate
Level / Temperature / Pressure Measurement & Control
Systems

www.tge-gas.com 24/10/2016 Page 5

PROJECT OVERVIEW – FLOW DIAGRAM

www.tge-gas.com 24/10/2016 Page 6

PROJECT OVERVIEW
MAIN PROJECT STEPS

Tank Design Hazop Review Meeting

Full Containment Design acc. EN14620 Safety Discussions Client & Vendors
Insulation Calculations 3D Model Review
Design of Equipment 30% 3D Model Review – Lines
Type 60% 3D Model Review – Maintability and Operability
Data Sheets 90% 3D Model Review – All Layout
Noise Study Compressor Shelter Safety Review by Inspecta
Restriction of Noise Review of Project Design regarding Overall Safety
Natural Ventilation e.g. Check of Safety Valve Sizing

www.tge-gas.com 24/10/2016 Page 7

PROJECT OVERVIEW - PROCESS
SPECIAL PROCESS DESIGN

Screw Compressors
Preheating of Cold Ethane Vapour
Shell & Tube Heater
Usage of Hot Compressor Discharge
Preheating to -40°C
Compressor Inlet Temperature controlled via Bypass
Safety System
Stop Compressor at low Temperature

www.tge-gas.com 24/10/2016 Page 8

PROJECT OVERVIEW - PLOTPLAN

www.tge-gas.com 24/10/2016 Page 9

CONSTRUCTION
STATISTICS ORGANIZATION

Duration 26 months (08.14. – 09.16) Daily Site Coordination Meetings

Number of Near Misses: 303 Weekly Meetings with CLIENT and Subcontractors
Total Hours Worked: 292.506 Weekly Safety Walks
Accidents: 0 Toolbox Meetings
Lost Working Hours: 0 Involvement of CLIENT and INSPECTA from the beginning

www.tge-gas.com 24/10/2016 Page 10

CONSTRUCTION
WORKS

www.tge-gas.com 24/10/2016 Page 11

CONSTRUCTION
MECHANICAL COMPLETION / PRE-COMMISSIONING

Deviation into Systems and Subsystems and Testpacks

Inspections
Line Cleaning
System Drying & Inerting
Instrument Loop
Interlock / ESD Checks
PID Checks
Electrical Circuit / Motor / Equipment Checks
Equipment Installation
Mechanical Equipment Checks
Vendor Checks
Introduce IA and N2 – Flush & Test
Service Test FW System – Flush & Test & Drain
Follow Up Done by PIMS CMS System

www.tge-gas.com 24/10/2016 Page 12

PRE-COMMISSIONING / COMMISSIONING
PRE-COMMISSIONING / COMMISSIONING

Start Half a Year in Advance with first Commissioning Tank Purging with Nitrogen
Meetings (Scope, Interfaces, Organization)
Tank Gassing-up & Start-up Compressors
Operator Training Support
Tank Cool Down
Dedicated Commissioning Team Full Time on Site
Start of In-tank Pumps
Start of Sendout

Performance Tests
Taking Over

www.tge-gas.com 24/10/2016 Page 13

COMMISSIONING
CHALLENGES

Integration of: Support

New DCS / SM into old DCS / SM DCS programming according TGE design
Equipment into old DCS / SM Adjustment of Control for Preheater System
Manual Control for Preheaters during Cooldown
Sensible Interaction between Components of System for
Adjustment
Observation of Behavior of the Control Systems during
Manual Control

www.tge-gas.com 24/10/2016 Page 14

IMPORTANT MILESTONES

www.tge-gas.com 24/10/2016 Page 15

THANK YOU FOR YOUR ATTENTION!

Vielen Dank cпaсибо большое

Obrigado
多谢

www.tge-gas.com 24/10/2016 Page 16

CONTACT
TGE Gas Engineering GmbH
Mildred-Scheel-Str. 1
53175 Bonn
Germany
+49 228 60448 0
+49 228 60448 893
www.tge-gas.com
tge-service@tge-gas.com

www.tge-gas.com 24/10/2016 Page 17

PRODUCT LINES

Storages and Storage and Small-Mid Scale Other

Terminals Terminals Natural Gas LNG Package Plants for gas
for LNG for Petrochemical/ Liquefaction Plants treatment or elements
Chemical Gas of storage product
lines
LNG as Fuel
Storage Tank
Design Services

www.tge-gas.com 24/10/2016 Page 18

FACTS & FIGURES
STORAGES AND TERMINALS FOR LNG

17 Projects in Total (EPC & EP+CS) STORAGE TANKS

Import Terminals: 9 Storage Tanks installed 30,000 - 160,000 m³

Export Terminals: 7 Storage Tanks designed 5,000 - 260,000 m³

Import/Export Terminal: 1 Storage Tanks installed in Europe 940,000 m³

72 LNG Truck/Container Loading Stations Storage Tanks installed in Asia 1,908,000 m³

Total Regasification Capacity > 13 mio t/a

Total Production Capacity INSTALLED CAPACITY
Small-Mid Scale LNG > 3 mio t/a
21 Full Containment Tanks 2,838,000 m³

5 Single Containment Tanks 170,000 m³

Reference for all relevant International Design Codes:
TOTAL INSTALLED CAPACITY 3,008,000 m³
Tanks: EN 14620, EUROCODE
API 625, API 620, ACI 376
Facilities: EN 1473, NFPA 59a, S

www.tge-gas.com 24/10/2016 Page 19

FACTS & FIGURES
STORAGES AND TERMINALS FOR
PETROCHEMICAL GASES
36 Projects in Total (EPC & EP+CS) for
Petrochemical Products: Ethylene, Ethane,
Propylene, Butane, LPG, Ammonia.

STORAGE TANKS
Tanks installed with capacities from
3,000 - 120,000 m³
up to

Facilities installed in Europe 327,000 m³

Facilities installed in Asia 1,684,000 m³ LARGEST INSTALLED CAPACITY

LPG 120,000 m³ Full Containment

INSTALLED CAPACITY
Ethylene 80,000 m³ Full Containment
20 Full Containment Tanks
1,205,000 m³
with installed capacity Ethane 120,000 m³ Full Containment
22 Single Containment Tanks
560,000 m³ Propylene 80,000 m³ Full Containment
with installed capacity

TOTAL INSTALLED CAPACITY 1,765,000 m³ Ammonia 25,000 ton Full Containment

www.tge-gas.com 24/10/2016 Page 20